Method of forming rail joints



Oct. 17, 1939. E; w, BACKES 2,176,287

METHOD OF FORMING RAIL JOINTS Filed May 18, 1936 2 Sheets-Sheet 1 ZZZ/6 b; Idward Wficzcfwza E. w. BACKES 2,176,287

METHOD OF FORMING RAIL JOINTS Oct. 17, 1939.

Filed May 18, 1936 2 Sheets-Sheet 2 Edward Wfiackea Patented Oct. 17, 1939 UNITED STATES PATENT QFFiCE METHOD OF FORMING RAIL JOINTS sey Application May 18, 1936, Serial No. 80,263

8 Claims.

The present invention relates to novel rail joint constructions, and more particularly to a novel method of producing the same.

Among the objects of the present invention is 5 to provide a novel method of forming rail joints which have become worn in service or on rails as yet unused whereby the splice or joint bars used in the joints have uniform fishing contact with the fishing surfaces provided on the rails to prom vide an efficient joint.

The present invention has as an object the idea of providing a novel method of forming rail joints equally applicable to worn or new rails which, when followed, produces a rail joint having 5 structural characteristics approaching those of a continuous rail.

Still another object of the present invention is to provide a novel method of forming rail joints on worn or new rails wherein the splice or joint 20 bars provided therefor fish over the fishing surfaces on the rails more uniformly and substantially equally and permanently and provide a positive contact therebetween which will greatly reduce or eliminate the abrasive wear therebe- 25 tween.

Another object within the purview of the present invention is to provide a novel method of forming rail joints on worn or new rails wherein the splice bars cooperate with the fishing sur- 30 faces provided on the rails in such a manner as to avoid the over-stressing of the parts of the rail joint assembly due to eccentricities of loading or pressure and wherein the dynamic augment, when shear reversal takes place at the rail joint,

35 is substantially eliminated and wherein a more accurate alignment of the abutting rail' ends is effected.

The present invention also comprehends novel rail joints formed from worn or new rails wherein the rails are reconditioned in accordance with 55 Figures 3 to 6 inclusive are end views of rails disclosing various conditions which may exist and cause variations in the fishing height of the rails on either or both faces thereof;

Figure 7 is a view in elevation of a section of a rail disclosing in an exaggerated manner one of 1 the variations which may exist in a rail whereby the fishing height thereof varies from point to point;

Figure 8 is a View in elevation of portions of rails disclosing variations in the fishing height of adjacent rails and the method followed in correcting this deficiency;

Figure 9 is a view in elevation of a rail joint disclosing more particularly the extent of fishing area of the splice bars; and 115 Figure 10 is a view in elevation similar to that shown in Figure 9 of the drawings, the same disclosing a different type of splice bar and the extent of its fishing with the rail ends.

The present invention comprehends a novel method of reconditioning worn or new rails to provide rail joints wherein the fishing surfaces of the adjacent rail ends are accurately aligned and wherein the splice bars which are provided at the rail joints more uniformly engage or contact these fishing surfaces to provide tight and permanent joints to greatly reduce abrasive wear between the splice bars and the rail ends and to prevent over-stressing of the parts of the rail joints due to eccentricities of loading or pressure and to substantially eliminate the dynamic aug- 'ment when shear reversal takes place at the rail ends.

After an exhaustive study of a large number of rail joints over an extended period of time and under a wide variation of conditions, I have found that appreciable differences exist between corresponding fishing heights on both sides of rail joints. For convenience, the results of this search are tabulated below to indicate the differences 40 which exist between these fishing heights on new and worn rails.

It is generally recognized by those familiar as with rail joints that where there is looseness between two abutting members, such as the splice bars and the rail ends in rail joints, which assemblies are subject to a load cycle including both positive and negative moments, that such looseness greatly accelerates the abrasion and wear of the surfaces in contact. Frown the results of the search tabulated above, it is apparent that differences between corresponding fishing heights of adjacently disposed rail ends when the tracks are newly laid are less than .005" in 51% of the cases, and that after service only about one-half of these, or 27%, remain in this group, the remainder of the original 51%, or 23%, moving into the next group. It is apparent, therefore, that 28% which are found in the second group when new become worn to such an extent as to be included within the next or higher group. It therefore appears that a difference in the fishing heights of somewhat less than .005" is necessary to provide tight rail joints which will remain in that condition and be fully effective over a long period of years.

It is therefore an object of the present invention to provide novel rail joints for new or worn rails which are tight and substantially permanent and in which the fishing surfaces are in accurate alignment and in uniform contact throughout, and a novel method of providing the same. In Figure l of the drawings, worn rails 2 and 4 are disclosed in their proper position for forming a rail joint, which rail joint may include splice bars (not disclosed, but may correspond to either of the splice bars of Figure 9 or Figure 10, as later described, or to any type using rail fishing surfaces) which are connected together and urged into fishing relation with the rail ends by means of bolts passing through openings, such as ii, formed in the web of the rails. As is well known, these rails include the web 8 through which the openings 6 extend, a rail head it and oppositely disposed flanges 52.

In measuring the fishing heights of rails, a uniform practice has been adopted as disclosed in Figure 2 of the drawings, wherein the fishing heights as indicated by lines M and it are measured vertically between the head and flanges of the rail on opposite sides of the web and at equal distances, represented by lines [8 and 29, from the vertical center plane of the rail.

In Figure 1 of the drawings rails 2 and 4 at the rail joint are shown as having fishing heights on one side thereof, as at 22 and 25, respectively, which fishing heights vary from one another. It may be that a similar condition exists between the fishing heights on the other side of the rail, that is to say, there may be a difference in the fishing heights which is approximately the same, or greater or less than as shown at 22 and 2 3. Furthermore, although fishing height 22 indicates greater wear on rail 2, nevertheless on the other hand rail 41 may show the greater wear. Such excessive wear as has taken place at the ends of these rails necessitates excessive maintainance and results in early replacement. However, such rails may be reconditioned, in accordance with the present invention to provide a suitable joint wherein excessive wear will be eliminated and replacement deferred. The present method evolved for reconditioning worn rails recognizes the fact that the variations between the fishing heights on one face of the rails and the fishing heights on the other face of the rails may be different, and accordingly the method followed contemplates the idea of reconditioning each face of the rail joint assembly independently of the other.

As an illustration of the manner in which a rail joint may be reconditioned in accordance with the present method, the rail joint as shown in Figure 1 of the drawings may be referred to. In following the method of the present disclosure, the lower fishing surface 28 on one flange of the rail t may be moved into alignment with the fishing surface 28 on the lower flange of the rail 2. After this alignment of these fishing surfaces has been effected, the rails 2 and 4 are clamped in fixed position, after which the upper fishing surfaces 35 and 32 of the rails 2 and i, respectively, are reformed to provide new fishing surfaces and 3%, respectively, whereby the fishing heights 38 and 58 of the rails on one face of the joint are uniform and free from variation, and wherein the new fishing surfaces 3t and 36 are in alignment. This reforming of the rails may be effected, for example, by using a grinding machine which in operation is aligned with the fishing surfaces 26 and 25, this grinding machine having an operating element which removes metal from the upper fishing surfaces of the rails to form the new ali ned fishing surfaces 35 and 35. After the rails have been reformed on one face of the joint, as indicated, the same method may be followed in reconditioning the rail on the other face of the joint to provide properly aligned fishing surfaces.

It is to be understood that the new fishing heights formed on the opposite face of the joint shown in Figure l are not necessarily formed to correspond to the fishing heights 38 and 59, but are to be similarly aligned with each other. After the splice bars are suitably formed and placed in position, the same may be drawn into intimate contact with the fishing surfaces of the rails as by means of bolts passing through the openings 6 of the rail webs. The extent of the fishing surfaces 3 3 and 36 of the rails depends entirely upon the type of splice bar which is used in the rail joint. For example, if a splice bar of the type disclosed in Figure 9 of the drawings is used, the new surfaces 3d and 36 would extend over the entire length of the bar, as indicated at 35 in that figure. On the other hand, if a splice bar of the type disclosed in Figure 10 of the drawings is used, these surfaces would be less and extend only as indicated at 3? in that figure.

The method above described, wherein the lower fishing surfaces of the rails are initially aligned for the purpose of forming a base or guide for reforming and aligning the upper fishing surfaces, is preferred, but nevertheless, if desired.

the upper fishing surfaces could be initially alignedas, for example, on new railand the lower fishing surfaces reformed.

A rail joint formed from worn rails in accordance with the above disclosure has all of the advantages her-einbefore enumerated.

As is well-known, various conditions may exist in the production of new rails which affect the fishing heights of adjacent rail ends when the same are placed in service. In Figure '7 of the drawings is disclosed a new rail 52 which has been rolled in accordance with well-known practices. Due to various conditions which will be pointed out more clearly hereinafter, the fishing height on one side of the rail, as for example at the plane represented by the line marked M, is different than the fishing height on the same side of the rail at the plane represented by the line marked 46. Should the continuous length of rail be cut at the planes 44 and 46 and that portion of the rail indicated as 48 be used with that portion of the rail indicated as 58 to form a rail joint, a condition would exist as clearly shown in Figure 8 of the drawings, wherein the fishing height 52 on the rail section 48 would be greater than the fishing height 54 on the rail section 50. Should these rail ends be connected by a splice bar without proper alignment of the fishing surfaces 62 and 53, looseness would exist between the bar and the rail ends to such an extent that excessive wear would take place and the bar would be subjected to stresses due to the passage of wheels thereover which would quickly wear the rail ends at the joint, necessitating frequent attention, and resulting in excessive maintenance charges and early replacement.

In accordance with the present invention this condition can be overcome by aligning the lower fishing surfaces 56 and 58 of the rail ends 48 and 50, as hereinbefore indicated, and reforming rail end 50 as by means of grinding or other convenient method to provide a fishing Surface 60 extending over the desired length of the rail end 50 to conform to the particular type of splice bar used and which surface will be in alignment with the fishing surface 62 of rail end 48 whereby the fishing height 64 will conform to the fishing height 52. The same method may be followed in properly aligning the fishing surfaces on the other face of the joint, if a similar condition exists. Suitable splice bars having the proper fishing surfaces may then be secured in position to provide a tight fitting joint which will eliminate the excessive wear between the bars and the rail ends and which will not be subject to excessive stresses upon application of load to the joint.

The causes for lack of uniformity of the fishing heights along a continuous rail may be due to a large number of conditions, a number of which have been indicated in Figures 3 to 6 inclusive of the drawings. Figure 3 of the drawings shows in an exaggerated form that variation of fishing height on the two faces of a rail may be due to a tilting of the head with respect to the base or vertical center line of the rail section. This results in an increase of the fishing height on one face of the rail and a corresponding decrease in the fishing height on the other face of the rail, which condition, if the same exists at the point of cutting of the continuous rail into various sections, will provide rail ends wherein the fishing heights may vary from the fishing heights of other rail ends with which the same may be associated in forming a rail joint, such a condition may arise from the manner in which rail is cooled; when, in the process of cooling, the rail is not permitted to stand in its normal position upon the base flange but is laid with one face down thus being supported at one edge of the rail head as indicated at 63 and on the corresponding edge of the base flange as indicated at 65.

Variation in fishing heights of rails may exist because of irregular wear of the rolls used in forming the same, and such a condition is represented in Figure 4 wherein the dimensions 64 and 66 on one face of the rail differ from the dimensions indicated as 68 and 18 on the other face of the rail.

Normal wear of the rolls between the start and end of production of a batch of rails with a given set of rolls will produce variations in the fishing heights as indicated at 12 and 14 of Figure 5 of the drawings wherein 14 represents the fishing height on rail produced at the beginning of such a run of production before the rolls are worn and 12 represents the fishing;

height on rail produced toward the end of such a run after the rolls have become worn.

Furthermore, the variation in the distance between rolls may produce rails having a sectional area represented as 16, which sectional area varies considerably from the sectional area indicated by 18 (Figure 6), thereby producing rails with variations in the fishing heights. This difference may result because of the eccentricity of one or both of the rolls which will cause a repeated increase and decrease in the thickness of the section for each revolution of the rolls. Furthermore, under or over compensation for normal wear of the rolls through adjustment of the distance between the rolls may account for this difference in the sections of rails produced.

Irregularity in the rate or amount of heat lost may also produce variations in the fishing heights of rails. Since the temperature when cooling begins and the rate at which the cooling takes place will affect the size and shape of an irregular piece of steel, differences in temperatures and rate of cooling between various portions of a rail will result, when cool, in differences in the fishing heights.

Also, inasmuch as rails are cut to length while still hot, the same are apt to be deformed slightly imediately adjacent the ends as a result of the cutting operation, and when such deformation takes place at the top of the flanges or on the under side of the head, a distinct difference in the fishing heights results.

Although as shown in Figure 8 of the drawings rail end 50 only is reformed to provide suitably aligned fishing surfaces for the rail joint on one face thereof, nevertheless it is to be understood that one or both of the rails may be reformed as by means of grinding or the like to provide suitably aligned surfaces for receiving the splice bars.

When rail joints are made in accordance with the present method, whether the rail ends be worn or in a new condition, the fishing heights are accurately measured to determine the relation of one to the other on one face of the rail and to ascertain whether a reforming of one or both of the rails is advisable. If reconditioning of one or both of the rails is necessary, the present invention indicates the manner in which the proper fishing heights can be provided on one face of the rail, after which the same procedure may be followed in producing proper fishing heights, independently of the first-named fishing heights, on the other face of the rail ends.

While I have herein described and upon the drawings shown an illustrative embodiment of the invention, it is to be understood that the invention is not limited thereto but may comprehend other constructions, arrangements of parts, details, features and method steps without departing from the spirit of the invention.

I claim:

1. A method of preparing rail ends forming a rail joint and which are each provided with upper and lower fishing surfaces, comprising the steps of aligning one of said surfaces of one of said rail ends with the corresponding surface of the other of said rail ends, and removing metal from at least one of said rail ends at the other of said surfaces to align said surfaces.

2. A method of'pr'eparing rail ends forming a rail joint and which are each provided with upper and lower fishing surfaces, comprising the steps of aligning the lower fishing surface of one of said rail ends with the lower fishing surface of the other of said rail ends, and removing metal from at least one of said rail ends at said upper fishing surface to align said surface with the upper fishing surface of said other rail end.

3. A method of forming a rail joint including rail ends which are each provided with'upper and lower fishing surfaces on the head and flange thereof defining unequal fishing heights, comprising the steps of aligning one of the surfaces of one of said rail ends with the corresponding surface of the other of said rail ends, reforming at least one of said rail ends at the other of said surfaces to align the other surfaces of said rail ends to provide substantially equal fishing heights, and securing a splice bar having fishing surfaces conforming to the aligned surfaces of said rail ends thereto.

4. A method of forming a rail joint including rail ends which are each provided with a centrally disposed web and upper and lower fishing surfaces on the head and flange thereof defining variable fishing heights, comprising the steps of aligning the lower fishing surface of one of the rail ends on one side thereof with the lower fishing surface of the other of said rail ends, reforming at least one of the rails at the upper surface on the sameside thereof to align "the same with the corresponding surface of the other rail end, fitting a splice bar having fishing surfaces conforming to the aligned surfaces of said rail ends, aligning the lower fishing surface of one of the rail ends on the other side'thereof with the lower fishing surface of the other of said rail ends, re-

forming at least one of the rails at the upper surface on said other side to align the same with the corresponding surface of the other rail end, fitting a splice bar having fishing surfaces conforming to said'last-named aligned surfaces of said rail ends, and securing said splice bars together.

5. A method of forming a rail joint including rail ends which are each provided with upper and lower fishing surfaces on the head and flange thereof defining unequal fishing heights, comprising the steps of aligning one of the lower fishing surfaces of one of said rail ends with the corresponding lower fishing surface of the other of said rail ends, reforming at least one of said rail ends at the other of said surfaces on the same side of said rail ends as said aligned lower fishing surfaces to align said other surfaces of said rail ends to provide substantially equal fishing heights, and securing a splice bar having fishing surfaces conforming to the aligned surfaces of said rail ends thereto.

6. A method of preparing rail ends forming a rail joint and which are each provided with a centrally disposed web and upper and lower fishing surfaces on each side of said web, comprising the steps of aligning one of said surfaces-on one side of one of the rail ends with the corresponding surface of the other of said rail ends, reforming at least one of the rail ends at the other of said surfaces on the same side of said rail ends to align said other of said surfaces, and reforming at least one of said. rail ends at least at one of said surfaces on the other side thereof to align corresponding surfaces on said other side of said rail ends.

'7. A method of forming a rail joint including rail ends which are each provided with a centrally disposed web and upper and lower fishing surfaces on the head and flange thereof defining variable fishing heights, comprising the steps of aligning one of said fishing surfaces of one of the rail ends on one side thereof with the corresponding surface of the other of said rail ends, reforming at least one of said rail ends at the other of said fishing surfaces on said side thereof to align said other of said fishing surfaces, fitting a splice bar having fishing surfaces conforming to the aligned surfaces of said rail ends, aligning one of said fishing surfaces of one of the rail ends on the.

other side thereof with the corresponding surface of the other of said rail ends, reforming at least one of said rail ends at the other of said fishing surfaces on said other side thereof to align said other of said fishing surfaces, fitting a splice bar having fishing surfaces conforming to said lastnamed aligned surfaces of said rail ends, and securing said splice bars together.

8. A method of forming a rail joint comprising independent and adjacently disposed rail ends providing a joint therebetween and each having a head provided with a wheel engaging surface and upper fishing surfaces, a web, and a base flange provided with a supporting surface and lower fishing surfaces, comprising the steps of aligning one of said surfaces of one of said rail ends with the corresponding surface of the other of said rail ends, removing material from at least one of said rail ends at least at one of said fishing surfaces on one side thereof to align corresponding fishing surfaces to provide uniform fishing heights not varying from each other by more than approximately .005 on said side of said rail ends, removing material from at least one of said rail ends at least at one of said fishing surfaces on the other side thereof to align corresponding fishing surfaces to provide'uniform fishing heights not varying from each other by more than approximately .005" on said other side of said rail ends, fitting splice bars having fishing surfaces conforming to the aligned surfaces on both sides of said rail ends, and securing said splice bars together and to said independent and adjacently disposed rail ends to provide a tight and substantially uniform contact between said bars and said rail ends throughout their coopcrating fishing surfaces.

EDWARD WILLIAM BACKES. 

